U.S. patent application number 13/460259 was filed with the patent office on 2013-07-25 for device and method for powder distribution and additive manufacturing method using the same.
This patent application is currently assigned to INDUSTRIAL TECHNOLOGY RESEARCH INSTITUTE. The applicant listed for this patent is Ji-Bin Horng, Ching-Chih Lin, Steven Lin, Wei-Lun Tai, Wen-Peng Tseng, Chuan-Sheng Zhuang. Invention is credited to Ji-Bin Horng, Ching-Chih Lin, Steven Lin, Wei-Lun Tai, Wen-Peng Tseng, Chuan-Sheng Zhuang.
Application Number | 20130186514 13/460259 |
Document ID | / |
Family ID | 48796257 |
Filed Date | 2013-07-25 |
United States Patent
Application |
20130186514 |
Kind Code |
A1 |
Zhuang; Chuan-Sheng ; et
al. |
July 25, 2013 |
Device and method for powder distribution and additive
manufacturing method using the same
Abstract
The present disclosure provides a device and method for powder
distribution and an additive manufacturing method, wherein
different size or kind of powders could be chosen to be
accommodated within a receptacle. The receptacle can uniformly mix
the powder by a rotation movement, pour out the powders by the
rotation movement and distribute the powders for forming a layer by
a translation movement. In another embodiment, the receptacle
further comprises a heating element for preheating the powders. Not
only can the present disclosure uniformly mix the powders so as to
reduce the thermal deformation and distribute the powder layer
compactly, but also can the present disclosure distribute different
kinds of powder in different layer so as to increase the diversity
in additive manufacturing.
Inventors: |
Zhuang; Chuan-Sheng;
(Taichung County, TW) ; Lin; Ching-Chih;
(Kaohsiung City, TW) ; Lin; Steven; (Tainan City,
TW) ; Tai; Wei-Lun; (Taichung City, TW) ;
Tseng; Wen-Peng; (Tainan City, TW) ; Horng;
Ji-Bin; (Tainan City, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Zhuang; Chuan-Sheng
Lin; Ching-Chih
Lin; Steven
Tai; Wei-Lun
Tseng; Wen-Peng
Horng; Ji-Bin |
Taichung County
Kaohsiung City
Tainan City
Taichung City
Tainan City
Tainan City |
|
TW
TW
TW
TW
TW
TW |
|
|
Assignee: |
INDUSTRIAL TECHNOLOGY RESEARCH
INSTITUTE
Hsinchu
TW
|
Family ID: |
48796257 |
Appl. No.: |
13/460259 |
Filed: |
April 30, 2012 |
Current U.S.
Class: |
141/11 ; 141/1;
141/311R; 141/82 |
Current CPC
Class: |
B29C 64/205 20170801;
B05C 19/005 20130101; B22F 1/0003 20130101; B29C 64/236 20170801;
Y02P 10/295 20151101; B05C 19/06 20130101; Y02P 10/25 20151101;
B29C 64/329 20170801; B23K 26/702 20151001; B01F 11/0002 20130101;
B33Y 30/00 20141201; B29C 64/153 20170801; B23K 26/342 20151001;
B05C 19/008 20130101; B33Y 40/00 20141201; B22F 3/1055 20130101;
B29C 64/241 20170801; B22F 2003/1056 20130101 |
Class at
Publication: |
141/11 ;
141/311.R; 141/82; 141/1 |
International
Class: |
B65B 1/04 20060101
B65B001/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 20, 2012 |
TW |
101102390 |
Claims
1. A powder distribution device, comprising: a feeder, or providing
at least one powder; a translation driver, for providing a
translational driving force; a rotation driver, for providing a
rotational driving force while being coupled to the translation
driver; and a receptacle, coupled to the rotation driver for
enabling the receptacle to receive the rotational driving force
from the rotation driver so as to be driven to perform a rotation
movement while being brought along to move with the rotation driver
in a linear translation movement by the translational driving
force, and the receptacle being provided for receiving at least one
powder therein for allowing the at least one powder to be poured
out of the receptacle by the rotation of the receptacle.
2. The powder distribution device of claim 1, wherein the feeder is
further configured with at least one container, and each container
is further formed with at least one feeding port.
3. The powder distribution device of claim 1, wherein the feeder is
further configured with at least one container and rotary table in
a manner that each said container is disposed on the rotary table
for selectively enabling one container selected from the at least
one container to be rotated to a position corresponding to the
receptacle.
4. The powder distribution device of claim 1, wherein the feeder
further comprises: a frame, formed with an internal space that is
being divided into a plurality of accommodating slots to be used
for storing different kinds of powder as each accommodating slot is
further formed with a feeding port; and a rotary element, coupled
to the frame for providing power to the frame so as to drive the
frame to rotate.
5. The powder distribution device of claim 4, wherein the cross
section of the frame is substantially a shape selected from the
group consisting of: a circle, a polygon.
6. The powder distribution device of claim 1, wherein the
receptacle further comprises: an opening, for allowing the at least
one powder to be fed into the receptacle therefrom and also for
allowing the at least one powder to be poured out of the receptacle
therefrom; a rotation shaft, coupling with the rotation driver to
be used as an axis of rotation; at least one heating element, each
being disposed inside the receptacle for heating the at least one
powder; and a temperature sensor, disposed inside the receptacle
for measuring temperature.
7. The powder distribution device of claim 1, wherein the
receptacle is enabled to rotate reciprocatingly for allowing powers
stored therein to be mixed fully and uniformly.
8. The powder distribution device of claim 1, further comprising: a
base, formed with a recess; and a lifting element, having a
platform slidably fitted in the recess for enabling the platform to
be driven to slide inside the recess by a lifting force from the
lifting element; wherein, by the linear translation movement of the
receptacle, the at least one powder that is being poured out of the
receptacle is distributed into a layer.
9. The powder distribution device of claim 8, further comprising: a
light source, capable of projecting and focusing a processing light
on the at least one powder that is disposed on the platform.
10. The powder distribution device of claim 1, wherein the rotation
driver is designed to receive the translational driving force so as
to be driven to perform a linear translation movement.
11. The powder distribution device of claim 1, wherein the at least
one powder that is being poured out of the receptacle is
distributed into a layer by the linear translation movement of the
receptacle.
12. The powder distribution device of claim 1, wherein the
translation driver is configured with a motor, a screw rod, a slide
seat and a slide block in a manner that the motor is coupled to the
screw rod by a coupling for enabling the screw rod to be powered
and driven to rotate by the motor, and the slide block is slidably
mounted on the slide seat while coupling to the screw rod so that
the slide block is enabled to slide on the slide seat by the screw
rod that is being driven to rotate by the motor.
13. The powder distribution device of claim 12, wherein the slide
block is coupled to the rotation driver via a connecting plate.
14. The powder distribution device of claim 1, wherein the rotation
driver is configured with a motor, a pair of pulleys and a belt in
a manner that the two pulleys are coupled respectively to the motor
and a rotation axis of the receptacle while enabling the belt to be
coupled to the pair of the pulleys.
15. A powder distribution method, comprising the steps of: using a
translation driver for driving a receptacle to move to a first
position; enabling a feeder to provide at least one powder to the
receptacle at the first position; using the translation driver for
driving the receptacle to move to a second position; and using a
rotation driver for driving the receptacle to rotate and thus
enabling the powder received in the receptacle to be poured out
from the same and deposited on the second position.
16. The powder distribution method of claim 15, wherein the feeder
is further configured with at least one container, and each
container is further formed with at least one feeding port.
17. The powder distribution method of claim 15, wherein the feeder
is further configured with at least one container and rotary table
in a manner that each said container is disposed on the rotary
table for selectively enabling one container selected from the at
least one container to be rotated to a position corresponding to
the receptacle.
18. The powder distribution method of claim 15, wherein the feeder
further comprises: a frame, formed with an internal space that is
being divided into a plurality of accommodating slots to be used
for storing different kinds of powder as each accommodating slot is
further formed with a feeding port; and a rotary element, coupled
to the frame for providing power to the frame so as to drive the
frame to rotate.
19. The powder distribution method of claim 18, wherein the cross
section of the frame is substantially a shape selected from the
group consisting of: a circle, a polygon.
20. The powder distribution method of claim 15, further comprising
the step of: using a heating element to perform a heating process
for heating the at least one powder while using the temperature
sensor to measure the temperature of the heating process.
21. The powder distribution method of claim 20, further comprising
the step of: using the rotation driver to drive the receptacle to
rotate during the heating process so as to enable the at least one
powder to be heated uniformly.
22. The powder distribution method of claim 15, further comprising
the step of: using the rotation driver to drive the receptacle to
rotate so as to enable a plurality of different kinds of powders to
be mixed fully and uniformly.
23. The powder distribution method of claim 15, further comprising
the step of: enabling the receptacle to be driven to move by the
translation driver for moving the receptacle across the poured-out
powder and thus distributing the poured-out powder into a layer on
a working area.
24. A powder distribution method, comprising the steps of: using a
translation driver for driving a receptacle to move to a first
position; enabling a feeder to provide at least one powder to the
receptacle at the first position; using the translation driver for
driving the receptacle to move to a second position; using a
rotation driver for driving the receptacle to rotate and thus
enabling the powder received in the receptacle to be poured out
from the same and deposited on the second position; enabling the
receptacle to be driven to move by the translation driver for
moving the receptacle across the poured-out powder and thus
distributing the poured-out powder into a layer on a working area;
and using the projection of a processing light that is produced
from a light source to perform an optical fabrication process upon
the layer of powder distributed on the working area.
25. The powder distribution method of claim 24, further comprising
the step of: changing the positioning of the working area in
altitude after each projection of the processing light is
completed.
26. The powder distribution method of claim 25, further comprising
the steps of: using the translation driver for driving a receptacle
to move to the first position; changing the kind of powder to be
received in the receptacle at the first position by enabling the
feeder to provide at least one other kind of powder that is
different from the previous powder to the receptacle at the first
position; using the translation driver for driving the receptacle
to move to the second position; using the rotation driver for
driving the receptacle to rotate and thus enable the powder
received in the receptacle to be poured out from the same and
deposited on the second position; enabling the receptacle to be
driven to move by the translation driver for moving the receptacle
across the poured-out powder and thus distributing the poured-out
powder into a new layer on top of the exiting layers of the working
area after the working area is being lowered by one layer
thickness; using the projection of the processing light to perform
an optical fabrication process upon the new layer of powder
distributed on the working area; and repeating the forgoing steps
until a part formed from successive layers of different materials
is completed.
Description
FIELD
[0001] The present disclosure relates to a device and method for
powder handling, and more particularly, to a device and method for
powder distribution and an additive manufacturing method using the
same.
BACKGROUND
[0002] The term additive manufacturing describes technologies which
can be used anywhere throughout the product life cycle from
pre-production (i.e. rapid prototyping) to full scale production
(also known as rapid manufacturing) and even for tooling
applications or post production customization. Accordingly,
Additive manufacturing (AM) is defined as the process of joining
materials to make objects from 3D model data, usually layer upon
layer, as opposed to subtractive manufacturing methodologies, such
as traditional machining. The first successful attempts at additive
manufacturing came from technology developed in the 1970s, and
since then the additive manufacturing technology is developing
rapidly with increasing industrial applications. Nowadays, there
are already a variety of AM techniques being developed, such as
three-dimensional printing (3DP), stereo lithography apparatus
(SLA), laminated object manufacturing (LOM), selective laser
sintering (SLS), selective laser melting (SLM), and fused
deposition modeling (FDM), etc.
[0003] Currently, the most well-known additive manufacturing
technique is the laser-based additive manufacturing (LBAM)
technique, such as the selective laser sintering (SLS) and the
selective laser melting (SLM). Taking a SLM process for example, it
is performed using a high power laser to fuse small particles of
plastic, metal, ceramic, or glass powders into a mass that has a
desired 3-dimensional shape. The laser selectively fuses powdered
material by scanning cross-sections generated from a 3-D digital
description of the part on the surface of a powder bed. After each
cross-section is scanned, the powder bed is lowered by one layer
thickness, a new layer of material is applied on top, and the
process is repeated until the part is completed. It is noted that
LBAM can produce relatively complex three-dimensional structures
like inner cavities and inner channels, which are normally
difficult or impossible for traditional manufacturing technologies
based on material removal. However, there are still issues to be
solved for improving the current additive manufacturing technique,
such as how to increase the density of the part being built, how to
increase the uniformity of deposition, how to get improvement in
the geometrical accuracy of the part being built, and how to
eliminate the thermal deformation due to the temperature variation
in the ambience, and so on.
[0004] There are already many studies focused upon the improvement
of additive manufacturing technique. One of which is an apparatus
for producing parts by selective sintering, disclosed in U.S. Pat.
No. 5,594,589, in which a powder dispensing mechanism including a
drum is used and enabled to move horizontally across the target
area and counter-rotated to smooth and distribute the powder in an
even layer across the target area, while also a downdraft system is
used for providing a controlled temperature air flow through the
target area to moderate powder temperature during sintering.
Moreover, there is a coating device provided in U.S. Pat. No.
5,730,925, which is configured with a bevel scraper or a round
scraper to be used for applying, smoothing and compacting the
solidified material on a layer. Similarly, there is an applicator
unit disclosed in U.S. Pat. No. 7,047,098, in which a flexible
means is used for applying a powder layer to a layer below it. In
addition, in U.S. Pat. No. 7,048,530, a shoe with a working surface
having specific indentations formed thereon to be used for applying
a powder layer is disclosed, which is arranged and adapted to
rotate and incline at an angle so as to spread and thus apply the
powder layer.
TECHNICAL SUMMARY
[0005] The present disclosure relates to a powder distribution
method and device, in which powders are received in a receptacle
for enabling the same to be poured out of the receptacle and piled
up on a specific position by a rotation movement of the receptacle
so as to be prepared to be distributed into a layer on a working
area by a linear translation movement of the receptacle.
[0006] The present disclosure further relates to a powder
distribution method and device, in which powders of different kinds
and different particle sizes are received in a receptacle for
enabling the same to be mixed uniformly by a rotation movement of
the receptacle, and then to be poured out and piled up on a
specific position by the rotation movement of the receptacle, so as
to be prepared to be distributed into a layer on a working area by
a linear translation movement of the receptacle. Consequently, by
enabling the powders to be fully and uniformly mixed by the
rotation movement of the receptacle, the compactness of the layer
formed by the distributed powder can be improved.
[0007] The present disclosure further relates to a powder
distribution method and device, in which either one kind of powder
of the same particle size or powders of different kinds and
different particle sizes are received in a receptacle that is
configured with a heating element in a manner that the powders in
the receptacle can be preheated uniformly by the heating element
while being mixed uniformly by a rotation movement of the
receptacle, and then to be poured out and piled up on a specific
position by the rotation movement of the receptacle, so as to be
prepared to be distributed into a layer on a working area by a
linear translation movement of the receptacle for preparing the
layer of powders to be processed by beams emitted from a light
source. It is noted that after each processing of one layer of
powders is completed, a new layer of powders different from the
previous layer in types or particle size is applied on top, and
then the process is repeated until a part formed from successive
layers of different materials is completed.
[0008] In an exemplary embodiment, the present disclosure provides
a powder distribution device, which comprises: a feeder, a
translation driver, a rotation driver and a receptacle. The feeder
is used for providing at least one powder. The translation driver
is used for providing a translational driving force. The rotation
driver is used for providing a rotational driving force while being
coupled to the translation driver so as to receive the
translational driving force for driving the rotation driver to
perform a linear translation movement. The receptacle is coupled to
the rotation driver for receiving the rotational driving force so
as to be driven to perform a rotation movement while being brought
along to move with the rotation driver in the linear translation
movement. Moreover, the receptacle is provided for receiving at
least one powder therein for allowing the at least one powder to be
poured out and piled on a specific position by the rotation
movement so as to be prepared to be distributed into a layer by the
linear translation movement of the receptacle.
[0009] In another exemplary embodiment, the present disclosure
provides a powder distribution method, which comprises the steps
of: using a translation driver for driving a receptacle to move to
a first position; enabling a feeder to provide at least one kind of
powder to the receptacle at the first position; using the
translation driver for driving the receptacle to move to a second
position; using a rotation driver for driving the receptacle to
rotate and thus enabling the powder received in the receptacle to
be poured out from the same and deposited on the second position;
and enabling the receptacle to be driven to move by the translation
driver for moving the receptacle across the second position and
thus distributing the powder deposited thereat into a layer on a
working area.
[0010] In another exemplary embodiment, the present disclosure
further provides a powder distribution method, which comprises the
steps of: using a translation driver for driving a receptacle to
move to a first position; enabling a feeder to provide at least one
kind of powder to the receptacle at the first position; using the
translation driver for driving the receptacle to move to a second
position; using a rotation driver for driving the receptacle to
rotate and thus enabling the powder received in the receptacle to
be poured out from the same and deposited on the second position;
enabling the receptacle to be driven to move by the translation
driver for moving the receptacle across the second position and
thus distributing the powder deposited thereat into a layer on a
working area; using the projection of a processing light that is
produced from a light source to perform an optical fabrication
process upon the layer of powder distributed on the working area;
and repeating the forgoing steps until a part formed from
successive layers of the same material is completed.
[0011] In another exemplary embodiment, in addition to and after
each projection of the processing light is completed, the powder
distribution method further comprises the steps of: changing the
kind of powder to be received in the receptacle at the first
position by enabling the feeder to provide at least one other kind
of powder that is different from the previous powder to the
receptacle at the first position; using the translation driver for
driving the receptacle to move to the second position; using the
rotation driver for driving the receptacle to rotate and thus
enable the powder received in the receptacle to be poured out from
the same and deposited on the second position; enabling the
receptacle to be driven to move by the translation driver for
moving the receptacle across the second position and thus
distributing the powder deposited thereat into a new layer on top
of the exiting layers of the working area after the working area is
being lowered by one layer thickness; using the projection of the
processing light to perform an optical fabrication process upon the
layer of powder distributed on the working area; and repeating the
forgoing steps until a part formed from successive layers of
different materials is completed.
[0012] Further scope of applicability of the present application
will become more apparent from the detailed description given
hereinafter. However, it should be understood that the detailed
description and specific examples, while indicating exemplary
embodiments of the disclosure, are given by way of illustration
only, since various changes and modifications within the spirit and
scope of the disclosure will become apparent to those skilled in
the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present disclosure will become more fully understood
from the detailed description given herein below and the
accompanying drawings which are given by way of illustration only,
and thus are not limitative of the present disclosure and
wherein:
[0014] FIG. 1 is a schematic diagram showing a powder distribution
device according to an exemplary embodiment of the present
disclosure.
[0015] FIG. 2A is a schematic diagram showing an exemplary feeder
designed for a powder distribution device of the present
disclosure
[0016] FIG. 2B and FIG. 2C are schematic diagrams showing
respectively the structure of another exemplary feeder of the
present disclosure and how the feeder is being assembled in a
powder distribution device of the present disclosure.
[0017] FIG. 2D is a schematic diagram showing further another
exemplary feeder with a hexagon frame used in the present
disclosure.
[0018] FIG. 3 is a three-dimensional diagram showing the assembly
of a translation driver and a rotation driver in the present
disclosure.
[0019] FIG. 4 and FIG. 5 are schematic diagrams showing
respectively two exemplary receptacles used in the present
disclosure.
[0020] FIG. 6 is a cross sectional view of another exemplary
receptacle used in the present disclosure.
[0021] FIG. 7 is a schematic diagram showing a powder distribution
device according to further another exemplary embodiment of the
present disclosure.
[0022] FIG. 8A to FIG. 8J are schematic diagrams showing
respectively steps performed in a powder distribution method
according to an exemplary embodiment of the present disclosure.
[0023] FIG. 8K is a schematic diagram showing how a light source is
adapted for focusing a processing light emitted therefrom onto a
layer on powder distributed on the working area for the proceeding
of an optical fabrication process in the present disclosure.
[0024] FIG. 9 is a schematic diagram depicting the relation between
the width of an opening formed on a receptacle and the area where
the powder can be distributed in the present disclosure.
[0025] FIG. 10 is a schematic diagram showing a part formed from
successive layers of different materials by the use of a device and
method for powder distribution of additive manufacturing according
to the present disclosure.
DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
[0026] For your esteemed members of reviewing committee to further
understand and recognize the fulfilled functions and structural
characteristics of the disclosure, several exemplary embodiments
cooperating with detailed description are presented as the
follows.
[0027] Please refer to FIG. 1, which is a schematic diagram showing
a powder distribution device according to an exemplary embodiment
of the present disclosure. As shown in FIG. 1, the powder
distribution device 2 comprises: a feeder 20, a translation driver
21, a rotation driver 22 and a receptacle 23, whereas the feeder 20
is used for providing at least one powder 90. In this exemplary
embodiment, the feeder 20 is further configured with at least one
container 200, while each container 200 is further formed with at
least one feeding port 201. In a condition when there is only one
such container 200 in the receptacle 20, the container 200 can be
used for storing a single kind of powder or a mixture of different
kinds of powders, and moreover, the powder can be formed with the
same particle sizes or with different particle sizes. In the
embodiment shown in FIG. 1, there are two containers 200 included
in the receptacle 20, which are to be used for receiving two
different kinds of powders in respective. Herein, the two different
kinds of powders can be different from each other in material or in
particle size. In addition, there are mechanisms built at positions
corresponding to the feeding ports 201 for controlling the opening
and close of the feeding ports 201, and since such open/close
mechanisms are known to those skilled in the art and thus will not
be described herein. It is noted that although there are only two
containers 200 shown in the embodiment of FIG. 1, the amount of
container 200 is not limited thereby, and thus can be determined
according to actual requirement.
[0028] Please refer to FIG. 2A, which is a schematic diagram
showing an exemplary feeder designed for a powder distribution
device of the present disclosure. In this embodiment, the
containers 200 of the feeder 20 are mounted on a rotary table 202,
whereas the rotary table is substantially a disc formed with a
plurality of inset holes 203 for a plurality of containers 200 to
be fitted therein. As shown in FIG. 2A, the rotary table 202 is
configured with a shaft 204 to be used for coupling with a rotary
element 205 so as to enable the rotary table 202 to be powered by
the rotary element 205 and thus rotate accordingly. In this
embodiment, there are four inset holes, and correspondingly there
are four containers 200 to be fitted respectively in those four
inset holes 203 respectively. However, it is not essential for each
and every one of the inset hole 203 to be fitted by one container,
only if there is at least one container 200 being mounted on the
rotary table 202. In addition, the rotary element 205 can
substantially be a driving device, such as a step motor or a servo
motor, or can be an assembly of a motor and a transmission
belt/chain, whichever is able to drive the rotary table 202 to
rotate. As shown in FIG. 2A, the rotary table is designed for
accommodating a plurality of such containers 200, and thereby, the
feeder 20 as a whole is capable of providing various powders of
different kinds or particle sizes to the receptacle 23 in a manner
that while being driven to rotate by the rotary element 20, one
container 200 having a specific powder stored therein can be
selected from the plural containers 200 mounted on the rotary table
202 and thus is being rotate to a position corresponding to the
receptacle 23, and thereafter, the feeding port 201 of the selected
container 200 is opened for enabling the specific powder to be fed
into the receptacle 23.
[0029] Please refer to FIG. 2B and FIG. 2C, which are schematic
diagrams showing respectively the structure of another exemplary
feeder of the present disclosure and how the feeder is being
assembled in a powder distribution device of the present
disclosure. In the embodiment shown in FIG. 2B and FIG. 2C, the
feeder 20a further includes a frame 206a and a rotary element 209.
It is noted that the cross section of the frame 206a can
substantially be formed in a shape selected from the group
consisting of: a circle, a polygon. In this embodiment, the frame
206a is substantially a column, which is formed with an internal
space that is being divided into a plurality of accommodating slots
207a to be used for storing different kinds of powder, and each
accommodating slot 207a is further formed with a feeding port 208a.
As shown in FIG. 2B and FIG. 2C, the feeding port 208a of each
accommodating slot 207a is formed on a side surface of the frame
206a that is corresponding to its accommodating slot 207a. In
addition. The rotary element 209 is arranged coupling to the frame
206a, and in this embodiment, the rotary element 209 is used for
powering and thus driving the frame 206a to rotate about a Z-axis
that is defined in a Cartesian coordinate system in FIG. 2C.
Similarly, the rotary element 209 can substantially be a driving
device, such as a step motor or a servo motor, or can be an
assembly of a motor and a transmission belt/chain, whichever is
able to drive the frame 206a to rotate.
[0030] Please refer to FIG. 2D, which is a schematic diagram
showing further another exemplary feeder with a hexagon frame used
in the present disclosure. In this embodiment, the frame 206b of
the feeder 20b, being a polygon-shaped column, is formed with a
cross section of hexagon, and thereby, there can be six
accommodating slots formed inside the hexagon-shaped column 206b.
Moreover, as there are six side-surfaces 207b on the hexagon-shaped
column 206b, there can be six feeding ports 208a formed
respectively on the six side-surfaces 207b at positions
corresponding to and communicating with the six accommodating slots
in respective. Moreover, the frame 206b is coupled to the rotary
element 209 by a side thereof for enabling the frame to be powered
and thus driven to rotate by the rotary element 209. Similarly,
there can be mechanisms built at positions corresponding to the
feeding ports 208a in the embodiment shown in FIG. 2B and FIG. 2D,
for controlling the opening and close of the feeding ports 208a,
and since such open/close mechanisms are known to those skilled in
the art and thus will not be described herein. Moreover, as shown
in FIG. 2B and FIG. 2D, the frame is formed with a plurality of
such containers accommodating slots, and thereby, the feeder as a
whole, such as the feeders 20a and 20b, is capable of providing
various powders of different kinds or particle sizes to the
receptacle 23 in a manner that while the frame 206a, 206b is being
controlled and driven to rotate about a Y-axis by the rotary
element 209, one accommodating slot having a specific powder stored
therein can be selected from the plural accommodating slot formed
on the frame 206a, 206b and thus is being rotate to a position
corresponding to the receptacle 23, and thereafter, the feeding
port 208a, 208b of the selected accommodating slot is opened for
enabling the specific powder to be fed into the receptacle 23.
[0031] It is noted that the translation drive 21, as the one shown
in FIG. 1, is used for providing a translational driving force.
Please refer to FIG. 3, which is a three-dimensional diagram
showing the assembly of a translation driver and a rotation driver
in the present disclosure. In FIG. 3, the translation driver 21 is
configured with a motor 210, a screw rod 211, a slide seat 212 and
a slide block 213, in a manner that the motor 210 is coupled to the
screw rod 211 by a coupling 214 for enabling the screw rod 211 to
be powered and driven to rotate by the motor 210, and the slide
block 213 is slidably mounted on the slide seat 212 while screwed
to the screw rod 211 so that the slide block 213 is enabled to
slide on the slide seat 212 by the screw rod 211 that is being
driven to rotate by the motor 210. It is noted that the translation
driver is provided solely for driving the receptacle 23 to move,
and thus in addition to the one disclosed in FIG. 3, it can be
achieved in another manner known to those skilled in the art, so
that the translation driver is not limited by the embodiment shown
in FIG. 3.
[0032] In the embodiments shown in FIG. 1 and FIG. 3, the rotation
driver 22 is coupled to the translation driver 21. Taking the
embodiment shown in FIG. 3 for example, the rotation driver 22 is
coupled to the slide block 213 for enabling the rotation driver 22
to receive the translational driving force from the translation
driver 21 and thus to be brought along to move in a linear
translation movement by the translational driving force. Moreover,
in this embodiment of FIG. 3, the slide block 213 is coupled with
the rotation driver 22 through a connecting plate 215. However, the
connecting plate 215 is just for achieving the connection between
the slide block 213 and the rotation driver 22, and thus it is not
an essential component for the present disclosure. The rotation
driver 22, being a device for providing a rotational driving force
to the receptacle 23 so as to brought along the receptacle 23 to
rotate, is configured with a motor 220, a pair of pulleys 221 and a
belt 222 in a manner that the two pulleys 221 are coupled
respectively to the motor 220 and the rotation axis of the
receptacle 23 while enabling the belt 222 to be coupled to the pair
of the pulleys. It is noted that the motor 220 can be a step motor
or a servo motor. As shown in FIG. 3. the receptacle 23 is coupled
to the rotation driver 22 for enabling the receptacle 23 to receive
the rotational driving force from the rotation driver 22 so as to
be driven to perform a rotation movement while being brought along
to move with the rotation driver 22 in a linear translation
movement by the translational driving force of the translation
driver 21. In the embodiment shown in FIG. 3 and FIG. 4, the
receptacle 23, being provided for storing the at least one powder,
is substantially a container having an opening 230 formed on top
thereof to be used as a powder inlet or outlet. In addition, the
receptacle 23 further has a rotation shaft 231 that is arranged
coupling with the rotation driver 22 for enabling the receptacle 23
to be driven to rotate by the rotation driver 22, and thereby,
enabling the rotation angle of the receptacle 23 to be controlled
by the rotation driver 22 through a controller controlling the
rotation driver 22. Moreover, the receptacle 23 can be a
cylinder-like structure, such as the circular-shaped cylinder shown
in FIG. 4, or the polygon-shaped cylinder shown in FIG. 5.
[0033] Please refer to FIG. 6, which is a cross sectional view of
an exemplary receptacle used in the present disclosure. In this
embodiment, the receptacle 23 is structured similar to those
disclosed in FIG. 4 or FIG. 5, but is additional being configured
with at least one heating element 232 and a temperature sensor 233,
in which each heating element 232 is used for preheating the at
least one powder 90 stored inside the receptacle 23; and the
temperature sensor 233 is disposed inside the receptacle 23 for
measuring temperature of the at least one powder 90 as the powder
is being heated the heating element 232 while transmitting the
result of the temperature measurement to a controller to be used as
a reference for determining whether to activate or deactivate the
heating element 232, or to adjust the heating power of the heating
element 232. Operationally, during the powder 90 is being preheated
by the heating element 232, the receptacle 23 is enabled to rotate
reciprocatingly for allowing power 90 stored therein to be heated
fully and mixed uniformly.
[0034] Please refer to FIG. 7, which is a schematic diagram showing
a powder distribution device according to further another exemplary
embodiment of the present disclosure. In addition to the structures
and components shown in FIG. 1, the powder distribution device in
this embodiment of FIG. 7 is further consisted of: a processing
unit 24 and a light source 25. The processing unit 24 includes: a
base 240, formed with a recess 242; and a lifting element 241,
having a platform 243 slidably fitted in the recess 242 for
enabling the platform 243 to be driven to slide inside the recess
242 by a lifting force from the lifting element 241, in which the
platform 243 is used as a powder bed for supporting the power that
is being distributed into a layer 900. In addition, the light
source 25 is provided for projecting and focusing a processing
light onto the layer of powder 900 that is deposited on the
platform 243. In this embodiment, the light source 25 is a laser
source capable of emitting a laser beam onto the layer of powder
for an additive manufacturing operation, such as a selective laser
sintering or a selective laser melting.
[0035] Please refer to FIG. 8A to FIG. 8J are schematic diagrams
showing respectively steps performed in a powder distribution
method according to an exemplary embodiment of the present
disclosure. The powder distribution method, which is adapted for a
powder distribution device 2, such as those disclosed in FIG. 1 to
FIG. 7, starts from the step show in FIG. 8A. At the step of FIG.
8A, a translation driver 21 is enabled for driving a receptacle 23
to move to a first position, whereas the first position is a
location corresponding a feeder 20 for allowing the receptacle 23
to receive powders that are discharged from the feeder 20.
Moreover, the area 93 shown in FIG. 8A is substantially a part in a
powder bed that is formed from successive layers of powder after
being treated by a plurality of optical fabrication processes, and
consequently the steps shown in FIG. 8B to FIG. 8J only represent a
procedure for distributing at least one powder into a new layer on
top of the powder bed, which can be any one layer of the successive
layers of powder in the powder bed. After the step of FIG. 8A, the
step shown in FIG. 8B is being executed. At the step of FIG. 8B, a
feeder 20 is enabled to provide at least one powder 90 to the
receptacle 23 at the first position. Under a condition when it is
only require one kind of powder for forming this new powder layer
on the powder bed, the filling of powder into the receptacle is
completed after the step shown of FIG. 8B is completed. However, if
the new layer of powder is formed by the use of more than two
powders in different particle sizes or kinds, the step shown in
FIG. 8C will be executed after the step of FIG. 8B. At step of FIG.
8C, the receptacle 23 is being driven to move to another first
position corresponding to another feeder 200a for allowing the
feeder 200a to feed a different powder into the receptacle 23.
Nevertheless, the abovementioned step of FIG. 8C is applicable only
to the powder distribution device of FIG. 1. On the other hand, for
those devices structured as those disclosed in FIG. 2A, FIG. 2B and
FIG. 2D, the receptacle 23 is not required to move to another first
position, but instead, after the receptacle 23 is fed by the powder
discharged from one accommodating slot of the feeder, the feeder is
enabled to rotate by the rotary element for enabling another
accommodating slot to be positioned corresponding to the receptacle
23 for allowing another kind of powder that is stored in this
accommodating slot to be fed into the receptacle 23.
[0036] After all the required powders are being fed into the
receptacle 23, the steps of FIG. 8D and FIG. 8E are executed. At
the steps shown in FIG. 8D and FIG. 8E, the receptacle 23 is being
driven to rotate within a specific range of angle by the rotary
driver 22 so as to enable powders received in the receptacle 23 to
mixed fully and uniformly. In addition, if the receptacle 23 is
being heated by a heating element 232, the rotation of the
receptacle 23 is able to enable the powders received in the
receptacle 23 to be heated evenly, as indicated in another
embodiment described above. However, if there is only one kind of
powder being received in the receptacle 23 and the single kind of
powder had already been preheated, or if the receptacle 23 has more
than two kinds of powders stored therein while those different
powders had already been mixed fully and preheated before being fed
into the receptacle 23, the steps of FIG. 8D and FIG. 8E can be
omitted from the powder distribution method. Thereafter, the step
shown in FIG. 8F is executed. At the step shown in FIG. 8F, the
translation driver 21 is activated for driving the receptacle 23 to
move to a second position, and thus the rotation driver 22 is
activated for driving the receptacle 23 to rotate for enabling the
powder 90 received in the receptacle 23 to be poured out from the
same and deposited on the second position into a pile of powder 94.
For ensuring the pile of powder 94 to be distributed evenly into a
layer on a working area 92, the opening 230 of the receptacle 23
should be formed in a width D larger than the width d of the
working area 92 so as to ensuring the pile of powder 94 to be
distributed in an area with a width larger than the width d of the
working area 92, as shown in FIG. 9.
[0037] After the step of FIG. 8F is completed, the step shown in
FIG. 8G is executed. At the step of FIG. 8G, the receptacle 23 is
being driven to rotate by the rotation driver 22 to a specific
condition that the receptacle 23 is positioned for allowing a
portion 234 of the outer shell of the receptacle 23 to engage with
the pile of powder 94 while the receptacle 23 is being brought
along to move in the linear translation movement. It is noted that
the portion 234 of the outer shell of the receptacle 23 can be a
curved surface or a flat surface. After the step of FIG. 8G is
completed, the steps shown in FIG. 8H and FIG. 8I is executed. At
the steps of FIG. 8H and FIG. 8I, the receptacle 23 is being driven
to move by the translation driver 21 for moving the receptacle 23
across the pile of powder 94 and thus distributing the pile of
powder 94 into a layer on the working area 92. In this embodiment,
the working area is the area corresponding to the recess 242 of the
base 240. It is noted that before executing the steps shown in FIG.
8H and FIG. 8I, the lowest point at the portion 234 of the outer
shell that is to be engaged with the pile of powder is spaced from
the working area by a gap h, so that when the receptacle 23 is
being driven to move in the linear translation movement across the
pile of powder 94, the pile of powder will be pushed to move by the
outer shell of the receptacle 23 so as to be spread over and
pressed tightly in the space sandwiched between the bottom of the
receptacle 23 and the working area 92 into a layer of powder. It is
noted that the gap h is adjustable by the lifting and lowering of
the lifting element 241. After the steps of FIG. 8H and FIG. 8I is
completed, the step shown in FIG. 8J is executed. At the step of
FIG. 8J, after a new layer of powder 95 being formed at the working
area 92 on top of the original powder bed, the receptacle 23 is
being driven to move again to the first position by the translation
driver 21 to be prepared for another powder distribution.
[0038] Furthermore, in another embodiment of the present
disclosure, in addition to the abovementioned steps of FIG. 8A to
FIG. 8J, the powder distribution method further comprises a step as
shown in FIG. 8K. At the step of FIG. 8K, a light source 25 is
provided for projecting and focusing a processing light 91 upon the
layer of powder 95 for performing an optical fabrication process
thereon. In this embodiment, the light source 25 can be a laser
device, which is capable of emitting a laser beam to be used as the
processing light 91. As shown in FIG. 8K, the processing light 91
can be directed and thus selectively projected upon a specific
position on the working area 92 for sintering or melting the powder
layer 95 to the exact geometry defined by a 3D digital description
of a part 93, and thereby, after being scanned by the processing
light 91, the powder in the area 930 of the powder layer 95 that is
being scanned by the processing light 91 is fused into a cross
section of the part while allowing the other area 931 that is not
scanned to remain physically and chemically unchanged. By repeating
the forgoing steps of FIG. 8A to FIG. 8K, the part 93 can be
constructed gradually from the successive layers of powder in a
layer-by-layer manner. Nevertheless, in this embodiment, the powder
being used for forming each and every powder layer 95 in each
repeating of the steps of FIG. 8A to FIG. 8K for constructing the
part 93 is always the same kind of powder, or a mixed powder of the
same ingredients, so that the final part 93 is a mass made from the
same material.
[0039] However, in another embodiment of the present disclosure,
each layer in the successive layers of powder can be made of
powders of different ingredients, that is, the powders for
different layers in the successive layers of powder can be
different from each other in kinds or in particle sizes.
Operationally, after completing the step of FIG. 8K and before the
process begins another repeating of the steps of FIG. 8A to FIG.
8C, the powder that is stored inside the receptacle is changed and
replaced by another kind of powder. For instance, if the powder
used in a current repeating of the steps of FIG. 8A to FIG. 8K is a
powder A, or a mixed powder of powder A and powder B, another
powder that is different from the powder A or the mixed powder of
powder A and powder B will be used in the next repeating of the
steps of FIG. 8A to FIG. 8K, such as a powder C, or a mixed powder
of powder C and powder D. Similarly, if the powder used in a
current repeating of the steps of FIG. 8A to FIG. 8K is a powder of
particle size A, another powder in different particle size that is
different from the powder of particle size A will be used in the
next repeating of the steps of FIG. 8A to FIG. 8K, such as a powder
of particle size B. Thereby, the final part 93 being fabricated is
a mass formed from successive layers of different materials. It is
noted that the aforesaid powder distribution method of additive
manufacturing can be applied for producing multi-layered
piezoelectric actuators, or for producing diffusion films.
Especially for the multi-layered piezoelectric actuator that is
generally a laminated structure composed of successive layers of
different materials, such as a three-layered structure of a layer
of ceramic, a layer of conductive material layer and a layer of
insulation material, the laminated structure of the multi-layered
piezoelectric actuator, that is formed from successive layers of
different materials, can be achieved by the use of the aforesaid
embodiments without the complexity of those conventional processes
for producing the same multi-layered piezoelectric actuators.
[0040] On the other hand, regarding to the production of diffusion
films, the aforesaid powder distribution method of additive
manufacturing is also favored, since the diffusion film today, that
is generally being used for enabling light from a light guide plate
to be evenly distributed so as to eliminate a mura effect, is
usually constructed as a multi-layer film composed of successive
layers of different materials. Please refer to FIG. 10, which is a
schematic diagram showing a part formed from successive layers of
different materials by the use of a device and method for powder
distribution of additive manufacturing according to the present
disclosure. For a diffusion film that is composed of a plural
layers of a N1 material while allowing a layer of a N2 material to
be sandwiched between any two neighboring layers of N1 material,
such as the four-layered diffusion film that is configure with two
layers of N1 material and two layers of a N2 material in a
alternating manner, as shown in FIG. 10, the four-layered diffusion
film can easily be achieved after four repeatings of the steps
shown in FIG. 8A to FIG. 8K.
[0041] With respect to the above description then, it is to be
realized that the optimum dimensional relationships for the parts
of the disclosure, to include variations in size, materials, shape,
form, function and manner of operation, assembly and use, are
deemed readily apparent and obvious to one skilled in the art, and
all equivalent relationships to those illustrated in the drawings
and described in the specification are intended to be encompassed
by the present disclosure.
* * * * *